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The Surprising Use Cases of Foam Material

Photo by Basil Samuel Lade on Unsplash

Foam is typically the first choice for designers and engineers when they’re searching for a soft surface to add to their product. Typically, they must either choose samples made of hand-cut foam or foam concocted from two-part chemistries. However, these aren’t always the right choices for designers. These foam options allow the softness that designers desire, but these types of foams have restrictions that can dismantle the original concept for a design.

When faced with these limitations, designers often turn away from foam altogether and search for another solution. Now designers and engineers are encouraged to consider more versatile options like injected-molded EVA foam, reaction-injected molded polyurethane, and compression-molded EVA foam. These processes are used for products that 3D-design features include soft, comfortable, durable, and resistant to environmental conditions.

EVA Is Adaptable for Any Design

The injection-molded EVA process combined with a closed-cell, the cross-linked structure makes PopFoam waterproof, durable, and exceedingly versatile.

The process of PopFoam starts with a tool injected into a heatable mold and then rapidly ejected after a certain amount of time. It is then left to contract to the designated size and dimensions in a customized cooling station.

The injection-molded EVA foam has been used to design more comfortable mid-soles in shoes, as well as create a more supportive high chair for children. PopFoam is used for novelty products like floating drink dinghies, wine holders, hitch covers, and spa pillows. One of the greatest uses of injection-molded EVA foam is the One World Futbol. A nearly indestructible soccer ball that can withstand harsh environments and still allow the children to play and enjoy.

For designers looking for a soft, comfortable surface solution, the injection-molded EVA process stands out because it must be cored out. Coring out areas of the foam allows it to be flexible enough to stick to the original design while remaining squishy and comfortable. Designers and engineers no longer have to choose which element to sacrifice.

Because these unique processes exist, designers are able to create more captivating, diverse, and original products. They are no longer limited to the restraints put in place by traditional foam. Instead, designers can get more creative and think outside of the box.